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An advanced composite housing for the F/A-18C/D Generator Converter Unit (GCU) has been developed. The composite housing directly replaces the existing aluminum housing, and provides lighter weight and improved thermal performance. The composite housing uses IM7/954-2A material, with embedded aluminum pin fins in selected areas for thermal management. A fabrication procedure for the composite housing was developed, using matched metal compression molding, with adhesive bonding of secondary components. Two prototype housings were fabricated and will be tested for qualification.

This paper provides an overview of the development of an organic matrix composite housing for an aircraft generator. The specific component discussed is the main housing for the F/A-18 C/D Generator Convenor Unit (GCU). This component fulfills both structural and thermal functions. The composite housing will be a direct replacement for the existing aluminum component, and will offer lighter weight and improved thermal performance, at a comparable cost. The composite housing will be consolidated by matched metal net molding, and will demonstrate the use of embedded metallic pin fins within the composite material to improve thermal performance. The paper addresses the design development, thermal and structural design verification analyses, material compatibility testing, and fabrication process development and tooling design.